That's some really nice work, man. How did you piece together the cover art? I'm really quite jealous. That's some fine craftsmanship that.

I rather miss making character sheets. It's been a long time since we've taken ours out of ms word, and we've been using plain statblocks for a good year now. I remember I had a shapeshifter with tabs that folded over my ability scores, melee damage, etc depending on what form I was in. I was fairly proud of that. Then he was written out before he even saw combat. Not my GMs finest hour.

And as a side note, I think my friend has those very same boxes for storing tokens. Perhaps minus the little paperclips in the lid. I wonder would he let me commandeer one? Shame we don't use minis, though. Our "minis" are 1cm cubes, which if we're lucky get a personalized icon and a letter glued to the top. Sometimes I miss the days we werent so lazy.

Edit: Very curious about the spell cards, too. Where did you find them?

I made them using these boxes here. Just a side note, the WoW TCG is pretty darn good too.
WoW TCG on Amazon

I then created a template using Microsoft Publisher 2007. I used a piece of legal sized paper because of the dimensions of the box. I then cut it down to the correct size and popped it in. No cutting required as there's a nice plastic sleeve that holds the cover. I can send anyone the Publisher file if you want it.

I then created my character sheet. I like to use online character sheets so that my character is always available if I forget it. I use the one here:
DNDSheet.net
It has a pathfinder sheet. I then set the printing preferences to remove the header and footer, I then shrunk it down to 80 or 70 percent, I forget which, and printed it. I then cut it so that it fits in the box.

The spell cards were created from the site Liz mentioned, thanks. It's a great site and such a useful tool. Here's the link again:
Perram's Spellbook
The only thing with the spellcards. You have to play with the printing preferences quite a bit to get them to print out perfectly. He gives you most of the instructions needed right on the site.

I wonder if dry erase or wet erase markers would work on the case plastic without causing damage...if so, you could have a slide in spell sheet or your encounter list, or journal on the things. Pretty cool idea.

I bought up a bunch of the boxes at a discount, and began making character folios for my players. Here is the first one I finished. This is such a great idea, you totally deserve awesome praise for it.

Also, I just made the template into a Word document. So you don't need Publisher anymore.

I didnt get the email.. You might want to consider posting it on mediafire or 4shared or something like that, if you are comfortable sharing it with the public. Also, I think d20pfsrd hosts files like this for download. :)